SR4800 – SR4803 - SR6000

User's Manual
___________________________________________________________________________________________________________________________________________________

EAGLETRONIC MTL2

SR4800, SR4803, SR6000

USER'S MANUAL
V2.1 – May 2006

www.eagletronicchargers.com

__________________________________________________________________________________________________________________________________________________

Page 1/19
 SR4800 – SR4803 - SR6000
User's Manual
___________________________________________________________________________________________________________________________________________________

INDEX
·1. SAFETY INSTRUCTIONS AND WARNINGS________________________4
·GENERAL_______________________________________________________________4
·SHOCK PREVENTION_____________________________________________________4
·BURN AND BODILY INJURY PREVENTION____________________________________5
·FIRE AND EXPLOSION PREVENTION_________________________________________5
·ARCING AND BURNING OF CONNECTOR_____________________________________5
·MEDICAL AND FIRST AID TREATMENT_______________________________________5
·2. DESCRIPTION OF THE CHARGER_______________________________6
·3. INSTALLATION OF THE CHARGER______________________________7
·AC INPUT CONNECTION___________________________________________________7
·AC INPUT VOLTAGE SELECTION 208/240/480VAC (ONLY FOR SR4803)____________8
·AC INPUT VOLTAGE SETTINGS_____________________________________________9
·4. HOW TO USE THE CHARGER
______________________________________________________________
12
·PROGRAMMATION OF THE GASSING POINT__________________________________12
·BATTERY CONNECTION – VOLTAGE CHECK AND AUTOSTART__________________13
·CHARGE OPERATION_____________________________________________________14
·SAFETY TIMER – EMERGENCY STOP________________________________________16
·AUTOMATIC DATA SAVING_________________________________________________16
·BLOWN FUSE DETECTION_________________________________________________17
·AUTOMATIC CHARGE TERMINATION________________________________________17
·AUTOMATIC SHUTDOWN ON BATTERY DISCONNECTION_______________________17
·EQUALIZE & REFRESH MODES_____________________________________________18
·MANUAL CHARGE TERMINATION___________________________________________20
·SCHEMATICS & TABLES
______________________________________________________________
20

__________________________________________________________________________________________________________________________________________________

Page 2/19
 SR4800 – SR4803 - SR6000
User's Manual
___________________________________________________________________________________________________________________________________________________

1. SAFETY INSTRUCTIONS AND WARNINGS

Before to start using your EAGLETRONIC MTL2 battery charger, please take the time to read
these instructions carefully.
The owner’s manual is an important part of the charger. It’s recommended to keep it in good
condition for the lifetime of the charger. It should be kept in a dry and clean place, always
available to the users.

To indicate important instructions, the following blocks are used throughout this manual.

This operation can be dangerous for the user.

This operation is important for the functionality and reliability of the charger.

GENERAL

Battery charging products can cause serious injury or death, or damage to other equipment or
property, if the operator does not strictly observe all safety rules and take precautionary
actions.
Safe practices must be learned through study and training before using this equipment.
Only qualified personnel should install, use, or service this equipment.

SHOCK PREVENTION

Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live

equipments can fatally shock a person. To protect against shock, have competent electrician
verify that the equipment is adequately grounded and learn what terminals and parts are
electrically HOT.

The body’s electrical resistance is decreased when wet, permitting dangerous current to flow
through the body. Do not work in damp area without being extremely careful. Stand on dry
rubber mat or dry wood and use insulating gloves when dampness or sweat cannot be
avoided. Keep clothing dry.

INSTALLATION AND GROUNDING - A power disconnect switch must be located at the

equipment. Check the data label for voltage and phase requirements. If only 3-phase power is
available, connect single-phase equipment to ONLY TWO WIRES of the 3-phase line.
DO NOT CONNECT the equipment grounding conductor to the third live wire of the 3-phase
line as this makes the equipment frame electrically HOT, which can cause a fatal shock.
If a grounding conductor is part of the power supply cable, be sure to connect it to a properly
grounded switch box or building ground. If not part of the supply cable, use a separate
grounding conductor. Don’t remove a ground prong from any plug. Use correct mating
receptacles. Check ground for electrical continuity before using equipment. The grounding
conductor must be of a size equal to or larger than the size of the line conductors.
CHARGING LEADS – Inspect leads often for damage to the insulation. Replace or repair
cracked or worn leads immediately. Use leads having sufficient capacity to carry the operating
current without overheating.
BATTERY TERMINALS – Do not touch battery terminals while equipment is operating.
SERVICE AND MAINTENANCE – Shut OFF all power at the disconnect switch or line breaker
BEFORE inspecting, adjusting, or servicing the equipment. Lock switch OPEN (or remove line
fuses) so that the power cannot be turned ON accidentally.

__________________________________________________________________________________________________________________________________________________

Page 3/19
 SR4800 – SR4803 - SR6000
User's Manual
___________________________________________________________________________________________________________________________________________________

Disconnect power to equipment if it is to be left unattended or out of service. Disconnect

battery from charger. Keep inside parts clean and dry. Dirt and/or moisture can cause
insulation failure. This failure can result in high voltage at the charger output.

BURN AND BODILY INJURY PREVENTION

The battery produces very high currents when short circuited, and will burn the skin severely
if in contact with any metal conductor that is carrying this current.
Do not permit rings on fingers to come in contact with battery terminals or the cell connectors
on top of the battery. Battery acid is very corrosive. Alwais wear correct eye and body
protection when near batteries.

FIRE AND EXPLOSION PREVENTION

When batteries are being recharged, they generate hydrogen gas that is explosive in certain
concentrations in air (the flammability or explosive limits are 4.1% to 72% hydrogen in air).
The spark-retarding vents help slow the rate of release of hydrogen, but the escaping
hydrogen may form an explosive atmosphere around the battery if ventilation is poor.
The ventilation system should be designed to provide an adequate amount of fresh air for the
number of batteries being charged. This is essential to prevent an explosion.
Always keep sparks, flames, burning cigarettes, and other sources of ignition away from the
battery recharging area. Do not break "live" circuits at the terminals of batteries. Do not lay
tools or anything that is metallic on top of any battery.
ARCING AND BURNING OF CONNECTOR
To prevent arcing and burning of the connector contacts, be sure the charger is OFF before
connecting or disconnecting the battery. The ammeter should NOT indicate current flow.

MEDICAL AND FIRST AID TREATMENT

First aid facilities and a qualified first aid person should be available for each shift for
immediate treatment of electrical shock victims.
EMERGENCY FIRST AID: Call phisician and ambulance immediately and use First Aid
techniques recommended by the American Red Cross.

DANGER: ELECTRICAL SHOCK CAN BE FATAL.

If person is unconscious and electric shock is suspected, do not touch person if he or she is
in contact with charging equipment, battery, charging leads, or other live electrical parts.
Disconnect power at wall switch and then use First Aid.
Dry wood, wooden broom, and other insulating material can be used to move cables, if
necessary, away from person.
IF BREATHING IS DIFFICULT, give oxygen.
IF NOT BREATHING, BEGIN ARTIFICIAL BREATHING, such as mouth-to-mouth.
IF PULSE IS ABSENT, BEGIN ARTIFICIAL CIRCULATION, such as external heart massage.

In case of acid in the eyes, flush very well with clean water and obtain professional medical
attention immediately.

__________________________________________________________________________________________________________________________________________________

Page 4/19
 SR4800 – SR4803 - SR6000
User's Manual
___________________________________________________________________________________________________________________________________________________

2. DESCRIPTION OF THE CHARGER

EAGLETRONIC MTL2 battery chargers have been designed to charge Lead-Acid batteries.
These units convert the AC input to a DC output at the correct voltage. The charge curve is of
the type Wa.

The operation of the EAGLETRONIC MTL2 chargers is managed by the new MTL2 Digital
Charge Controller, which is a microprocessor based electronic board of the last generation.
Important features of the MTL2 Digital charge controller are:

− Easy Programmation by DIP switches.

− Programmable Gassing Voltage.
− Proportional Algorithm for charge time calculation.
− Programmable Equalize System (Automatic Pulsed & Manual).
− Automatic voltage-controlled maintenance.
− Wrong battery detection.
− Battery desulphation cycle.
− Independent safety timer.
− Automatic data-saving in case of black out of the mains.
− Cyclical indication of V/cell, AMPS, Ah returned, time.
− Cool down time counter.
− Scrolling messages in plain text.

The MTL2 Charge Controller monitors the entire charging curve, and it incorporates several
safety features.

The front panel of the MTL2 Digital charge controller contains the digital display (4-Digits), the
STOP button and the MANUAL-EQUALIZE button.

__________________________________________________________________________________________________________________________________________________

Page 5/19
 SR4800 – SR4803 - SR6000
User's Manual
___________________________________________________________________________________________________________________________________________________

3. INSTALLATION OF THE CHARGER

Conditions of use:

• Operating temperature: 5°C to 45°C

• Storage temperature: -20°C to 60°C
• Relative humidity: less than 75%
•

CAUTION!

Risk of electrical shock!

The charger can be installed by qualified personnel only.

To prevent fire or shock hazard, do not expose the unit to rain or moisture.
Don't use the unit in presence of flammable gas, because it can generate sparks.
ATTENTION!

Make sure that the unit's maximum input power (reported on the data label) is available from
your power supply, and verify that the unit's operating voltage is correct.
Allow adequate air circulation to prevent internal heat buildup.
Don't place the unit near heat sources such as radiators or air ducts, or in a place subject to
direct sunlight, excessive dust, mechanical vibration or shock.

AC INPUT CONNECTION

__________________________________________________________________________________________________________________________________________________

Page 6/19
 SR4800 – SR4803 - SR6000
User's Manual
___________________________________________________________________________________________________________________________________________________

The charger must be connected to the AC input using an adequate cable and plug, with
disconnect switch and fuses.

The AC input wires have to be connected to the TERMINAL BLOCKS FOR AC INPUT WIRES,
that are located on the right side of the internal panel, just under the AC input contactor.

Make sure to tighten the terminal block screws with the proper torque, and pull each wire
separately in order to verify that they are mounted properly.

AC INPUT VOLTAGE SELECTION 208/240/480VAC (ONLY FOR SR4803)

The model SR4803 can be configured for 208/240 VAC or 480 VAC nominal input voltage.

This selection can be made with the 220-240 / 480 VAC SELECTION BOARD, that is located at
the center of the internal panel, near the terminal blocks for the AC input wires.

• Disconnect the charger from main supply and battery.

• Remove the plastic protection over the 220-240 / 480 VAC SELECTION BOARD.
• Remove the three metal bars.
• Place the metal bars in the required position, with ref to the following pictures.
• Tighten the nuts with the proper torque.
• Apply the plastic protection.
• Connect the charger to main supply.

SELECTION BOARD SELECTION BOARD

IN POSITION IN POSITION
208-240 VAC 480 VAC

__________________________________________________________________________________________________________________________________________________

Page 7/19
 SR4800 – SR4803 - SR6000
User's Manual
___________________________________________________________________________________________________________________________________________________

AC INPUT VOLTAGE SETTINGS

ATTENTION!

The proper setting of the power transformer taps is fundamental

for the correct operation of the EAGLETRONIC MTL2 chargers.

If the real AC input voltage is different than the AC nominal voltage to which the charger is set,
the charging current of the charger may be significantly different than the nominal.

• The POWER TRANSFORMER TAPS and the label with the list of the 5 NOMINAL
voltages that are available, are located on the left side of the internal panel.

SR2400 SR4800 SR6000

1 1x 250 VAC
2 1x 240 VAC
3 1x 224 VAC
4 1x 208 VAC
5 1x 200 VAC
3x 250 VAC --- 3x 500 VAC 3x 620 VAC
3x 240 VAC --- 3x 490 VAC 3x 610 VAC
3x 224 VAC --- 3x 480 VAC 3x 600 VAC
3x 208 VAC --- 3x 460 VAC 3x 575 VAC
3x 200 VAC --- 3x 440 VAC 3x 550 VAC

• Using an adequate AC-voltmeter, measure the value of the REAL AC input voltage
available at the mounting location of the charger.

• Identify which of the 5 NOMINAL voltage values is closest to the REAL measured value.

Example 1: for a charger SR2400 (singlephase) if the measured voltage is 212

VAC, the transformer should be connected to the tap number 4, that
corresponds to 208 VAC.
Example 2: for a charger SR6000 (threephase) if the measured voltage is 608 VAC,
the transformer should be connected to the tap number 2, that
corresponds to 610 VAC

• For the singlephase units (SR2400), the wires to be moved are the TWO that are
connected to the AC contactor, marked with the letter “A”.

• For the threephase units (SR4803 – SR6000), the wires to be moved are the THREE that
are connected to the AC contactors, marked with the letters “A”, “B” and “C”.

__________________________________________________________________________________________________________________________________________________

Page 8/19
 SR4800 – SR4803 - SR6000
User's Manual
___________________________________________________________________________________________________________________________________________________

Singlephase units (SR2400)

Threephase units (SR4803 & SR6000)

__________________________________________________________________________________________________________________________________________________

Page 9/19
 SR4800 – SR4803 - SR6000
User's Manual
___________________________________________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________________________________________

Page 10/19
 SR4800 – SR4803 - SR6000
User's Manual
___________________________________________________________________________________________________________________________________________________

4. HOW TO USE THE CHARGER

PROGRAMMATION OF THE GASSING POINT

ATTENTION!

The proper programmation of the gassing point is important

for the correct operation of the EAGLETRONIC MTL2 chargers.

Only expert users should modify these settings.

The possibility to program the gassing point may help the user to adjust the charging curve to
the requirements of the battery during all its life. The default value is 2.40 Volt/cell.

This value can be modified by moving two dipswitches that are located on the MTL board,
near the microprocessor and the black heatsink (see next picture).
The dipswitch unit has 4 switches: the two central switches (number 2 and number 3) are
used for the programmation of the gassing point.

To modify the value, follow these steps:

• Disconnect the charger from main supply and battery.

• Locate the dipswitches on the digital electronic board (see next picture).
• Set the dipswitches according with the following table and pictures.
• Connect the charger to main supply.

__________________________________________________________________________________________________________________________________________________

Page 11/19
 SR4800 – SR4803 - SR6000
User's Manual
___________________________________________________________________________________________________________________________________________________

GASSING
DS #2 DS #3
POINT
0 0 2.35 V/cell
0 1 2.40 V/cell
1 0 2.45 V/cell
1 1 2.50 V/cell

When a battery will be connected to the charger, the programmed gassing voltage will be
shown on the display during the startup sequence.

BATTERY CONNECTION – VOLTAGE CHECK AND AUTOSTART

ATTENTION!

Eagletronic MTL2 chargers are programmed to execute a complete cycle of charge

automatically, however it’s recommended to survey the operations when the battery remains
connected to the charger for more than 12 hours (example: week-ends).

__________________________________________________________________________________________________________________________________________________

Page 12/19
 SR4800 – SR4803 - SR6000
User's Manual
___________________________________________________________________________________________________________________________________________________

Connect the battery to the charger, using an adequate plug.

When the battery is correctly connected, the display turns on and shows the battery voltage.

If the battery voltage lower than the minimum threshold of 1,62 V/cell, the charger doesn't
start, and the display will show the error message “Voltage Low”:

If the battery voltage is higher than the maximum threshold of 2,60 V/cell, the charger doesn't
start, and the display will show the (flashing) error message “Voltage High”:

If the voltage of the battery is between the minimum and maximum thresholds, the charger
will wait for 3 seconds before to start charging, while the display will show the programmed
gassing voltage.

If, during the charge, the voltage of the battery exceeds the maximum threshold of 2,80 V/cell,
the charger shuts down automatically, and the errore message “Voltage High” will appear on
the display.

CHARGE OPERATION

When the charge is started, the digital display will start showing
the following parameters:

• Voltage per cell of the battery (U) (Volt);

• Charge current; (A) (Ampere);
• Capacity charged; (C) (Ah);
• Time of charge. (h) (Hours);

During all the charge cycle these parameters are displayed in

sequence, as indicated in the picture.

The letter (U-A-C-h) indicates which parameter being is displayed.

To display the time, the charger uses this format:

(HOURS) . (MINUTE DECADES) h

Examples:
__________________________________________________________________________________________________________________________________________________

Page 13/19
 SR4800 – SR4803 - SR6000
User's Manual
___________________________________________________________________________________________________________________________________________________

Time of charge 3h 30minutes: Displayed 3.3h

Time of charge 7h 50minutes: Displayed 7.5h

• The charge current follows the Wa curve, as described in the norm DIN 41774, while the
charge parameters continue to be shown on the digital display.

__________________________________________________________________________________________________________________________________________________

Page 14/19
 SR4800 – SR4803 - SR6000
User's Manual
___________________________________________________________________________________________________________________________________________________

When the battery reaches the gassing voltage, the charge continues for one half of the time
needed to reach the gassing voltage, with a minimum total time of 30 minutes.

Examples:
• if the battery reaches the gassing voltage in 1 minute, the final charge will
continue for 30 minutes.
• if the battery reaches the gassing voltage in 5 hours, the final charge will
continue for 2 hours and 30 minutes.
• if the battery reaches the gassing voltage in 10 hours, the final charge will
continue for 5 hours.
• If the battery reaches the gassing voltage in 11h59m59s, the final charge will
continue for 5h 59m59s (this is the maximum total time allowed before going
to Emergency state).
These time limits are ok to use the charger with different battery capacities
(depending on the time available for the charge, from 8 to 16 hours), and it’s not
needed to do adjustments on the board.

SAFETY TIMER – EMERGENCY STOP

• If the battery doesn't reach the gassing voltage within 12 hours, the charge is terminated by
the safety timer, and the display shows the error message “Time Error”:

If this error message appear, it's recommended to call the service for a complete check of the
system.

The cause if this problem may be a wrong setting of the input voltage: if the input is set to a
certain value (for example: 610 V) but the real voltage is lower (for example: 575 V), the
charging current will be significantly lower than the nominal value, thus causing a longer time
to reach the gassing voltage.

AUTOMATIC DATA SAVING

• If, during the charge or equalization, one or more black-outs of the mains happen, the
microprocessor automatically saves all the relevant informations about the state of the
charge.
While the input power is absent and the battery is connected to the charger, the display will
show the message “Black Out”:

• When the power supply will be available again, the charger will re-start automatically from
the exact point of interruption, and the charge will be normally completed.

__________________________________________________________________________________________________________________________________________________

Page 15/19
 SR4800 – SR4803 - SR6000
User's Manual
___________________________________________________________________________________________________________________________________________________

BLOWN FUSE DETECTION

• If the output fuse is blown or absent, the display will show the message “Fuse”:

This message may appear also if the battery has been left discharged for long time, causing
the sulphation process on the plates.

AUTOMATIC CHARGE TERMINATION

CAUTION!

NEVER disconnect the battery while it's being charged.

Disconnecting the battery while it's being charged is hazardous
for the user and voids the charger warranty.

• When the charge is complete, the charger shuts down, and the display shows the scrolling
message “End Elapsed x.x h”.

The time indicated by the display is the time elapsed after the charge has been terminated.

This indication is useful when there are two or more forklift operated with FIFO (First In First
Out) rotation: when the user picks up a forklift, he will always chose the one with highest he
time elapsed after charge termination.

The final values of Voltage/cell, time of charge and capacity charged remain stored in
memory. If the red STOP pushbutton is pressed, the display will show these values in
sequence.

AUTOMATIC SHUTDOWN ON BATTERY DISCONNECTION

CAUTION!

NEVER disconnect the battery while it's being charged.

Disconnecting the battery while it's being charged is hazardous
for the user and voids the charger warranty.

If the battery is disconnected while the charge is in progress, the EagleTronic MTL2 switches
off automatically.

__________________________________________________________________________________________________________________________________________________

Page 16/19
 SR4800 – SR4803 - SR6000
User's Manual
___________________________________________________________________________________________________________________________________________________

EQUALIZE & REFRESH MODES

ATTENTION!

The proper programmation of the equalize & refresh modes is important

for the correct operation of the EAGLETRONIC MTL2 chargers.

Only expert users should modify these settings.

Eagletronic MTL2 chargers have a complete set of programmable equalize & refresh
functions:

− MANUAL EQUALIZE: 4 hours extension of the charge time (selected by user)

− DAILY EQUALIZE: 4 hours extension of the charge time (everyday)
− AUTO EQUALIZE & REFRESH: Weekly equalize cycle + long term battery refresh

MANUAL EQUALIZE

The MANUAL EQUALIZE function is intended for the users that prefer to manage the
equalization of the batteries personnally.

It will extend the time of the charge cycle by 4 hours, and it can be enabled by pushing the
apposite button, located on the right side of the front panel, during the first minutes of
charge.

The display will add the message “Eq. On” to the cyclical visualization of the charge
parameters, and the charge will proceed normally.

Once the manual equalize has been selected, the only way to deselect it is to disconnect and
re-connect the battery.

DAILY EQUALIZE

The DAILY EQUALIZE function will extend all the charge cycles by 4 hours, and it's suitable to
recover batteries that are lightly sulphated.

It can be enabled by moving the internal DIPSWITCH #1 to position ON (see the description of
the programmation dipswitches in the previous paragraphs).

The DAILY EQUALIZE function is DISABLED by default.

Since the DAILY EQUALIZE is a very intense equalize program and may tend to overcharge
the battery, it's recommended to limit it to short periods, then to return to a normal equalize
program.

__________________________________________________________________________________________________________________________________________________

Page 17/19
 SR4800 – SR4803 - SR6000
User's Manual
___________________________________________________________________________________________________________________________________________________

It's also recommended to survey the operation of the charger and keep the temperaure of the
battery under precise control while the DAILY EQUALIZE function is enabled.
AUTO EQUALIZE + REFRESH

The AUTO EQUALIZE + REFRESH function is totally managed by the MTL2 microcontroller.

It can be enabled by moving the internal DIPSWITCH #4 to position ON (see the description of
the programmation dipswitches in the previous paragraphs).

The AUTOMATIC EQUALIZE + REFRESH is ENABLED by default.

If the charge has been completed normally, the charger will add 5 short additional charge
cycles of 30 minutes, with 14 hours and 30 minutes interval between each charge.

During the time interval between each equalization charge, the display will show the scrolling
message: “End Elapsed x.x h”:

When the equalization chargers are in progress, the display will show the scrolling message:
“ equalization charge”:

followed by the indication of the charge current.

REFRESH OPERATION

If a battery is not used for a long time (example: seasonal works, holiday periods), it should
be kept well charged to avoid a reduction of performance, therefore it's very important to
charge the battery before leaving it in stock for more than 24 hours.

The self-discharge process makes it harder to keep a battery charged when the time of
stocking is longer (weeks or months). The REFRESH function is useful to keep the battery in
perfect condition when it's not used for an indefined time.

It is sufficient to leave the battery connected to the charger after the charge and the
equalization is complete.

The Eagletronic MTL2 microprocessor will keep the battery voltage under control and will
activate the charger automatically if the voltage drops below a predefined minimum theshold.

While the battery is monitored by the charger, the display will show the scrolling message
“Volt Control”:

__________________________________________________________________________________________________________________________________________________

Page 18/19
 SR4800 – SR4803 - SR6000
User's Manual
___________________________________________________________________________________________________________________________________________________

If the voltage drops down below the minimum threshold, the charger will give an extra charge
cycle to keep the battery in perfect condition, and the display will show the scrolling
message: “Refresh”.

Each Refresh charge terminates when the battery voltage reaches a predefined maximum
threshold.

• NOTE: With this “voltage controlled” refreshing system, the battery will be kept in perfect
condition for an undefined time, without any risk of undercharge or overcharge.
If the battery is in ideal condition (self-discharge absent) the refresh charge will never be
activated. In the opposite case, if the battery is in bad condition and the self-discharge is
significant, the refresh charge will be often activated and the battery will be kept charged
without problems.

les are completed, the charger passes to REFRESH mode.

MANUAL CHARGE TERMINATION

CAUTION!

NEVER disconnect the battery while it's being charged.

Disconnecting the battery while it's being charged is hazardous
for the user and voids the charger warranty.

While the charge is in progress, it's possible to shut down the charger by pressing the red
button “MANUAL STOP” on the front panel.

The display will show the message “Stop”:

• The final values of Voltage/cell, Time of charge and Capacity Charged remain stored in
memory. If the “MANUAL STOP” button is pressed again, these values will be displayed in
sequence.

When the charge is terminated manually, the equalization and refresh functions are
automatically disabled.

__________________________________________________________________________________________________________________________________________________

Page 19/19